1993 DODGE TRUCK Service Repair Manual

14
- 46
FUEL
SYSTEM

Fig.
12
Rubber
L-Shaped
Fitting—MAP
Sensor-to-
Throttie
Body

Fig.
13
Engine
Coolant
Temperature
Sensor—
Typical
EXHAUST
~~

PIPE
J9214-5

Fig.
14
Single
Oxygen
Sensor
Location-3.9U5.2L/ 5.9L LDC
Engine

(23) Inspect for pinched or leaking fuel tubes. In­
spect for pinched, cracked or leaking fuel hoses. •

Fig.
15
Dual
Oxygen
Sensor
Location—5.9L HDC
Engine
(24) Inspect for exhaust system restrictions such as
pinched exhaust pipes, collapsed muffler or plugged catalytic convertor.
(25) If equipped with automatic transmission, ver­
ify that electrical harness is firmly connected to
park/neutral switch. Refer to Automatic Transmis­ sion section of Group 21.
(26) Verify that the harness connector is firmly
connected to the vehicle speed sensor (Fig. 16).

Fig.
16 Vehicle
Speed
Sensor—
Typical

(27) Verify that fuel pump/gauge sender unit wire
connector is firmly connected to harness connector.
(28) Inspect fuel hoses at fuel pump/gauge sender
unit for cracks or leaks.
(29) Inspect transmission torque convertor housing
(automatic transmission) or clutch housing (manual
transmission) for damage to timing ring on drive
plate/flywheel. (30) Verify that battery cable and solenoid feed
wire connections to the starter solenoid are tight and clean. Inspect for chaffed wires or wires rubbing up against other components.

•
FUEL SYSTEM 14-47 POWERTRAIN CONTROL MODULE (PCM)
60-WAY

CONNECTOR
Terminal identification and specific circuit applica­
tions are shown in the PCM connector chart (Fig.
17).
Also refer to Group 8W, Wiring Diagrams.
SYSTEM
SCHEMATICS

Fuel system schematics for fuel injected engines
are shown in figures 18, 19 and 20.

CAV

WIRE

COLOR DESCRIPTION
CAV
WIRE

COLOR DESCRIPTION

1 DG/RD*
MAP SENSOR 37
BK/OR OVERDRIVE LAMP
2 TN/BK*
ENGINE COOLANT TEMPERATURE SENSOR 38 PK/BK INJECTOR DRIVE
#5

3 RD/WT DIRECT BATTERY 39 GY/RD IAC MOTOR
#4

4
BK/LB*

SENSOR RETURN 40 BR/WT
IAC MOTOR
#2

5 BK/WT SIGNAL GROUND 41
BK/DG* OXYGEN SENSOR SIGNAL
6 VT/WT
5-VOLT
OUTPUT
(MAP AND TPS)
42
7 OR

8-VOLT
OUTPUT (DISTRIBUTOR PICK-UP) 43

GY/LB*
TACHOMETER SIGNAL OUTPUT (VEHICLES W/TACHOMETER)
8 44 GY CAMSHAFT POSITION SENSE
9 DB
J2-IGNITION FEED 45
LG SCI RECIEVE
10 R/WT OVERDRIVE OVERRIDE
46 CCD
(-)

11 BK/TN POWER GROUND 47 WT/OR* SPEED SENSOR SIGNAL
12 BK/TN POWER GROUND 48 BR/RD* SPEED CONTROL
SET
SWITCH
13 LB/BR
INJECTOR DRIVER
#4
49
YL/RD* SPEED CONTROL ON/OFF SWITCH
14 YL/WT
INJECTOR DRIVER
#3
50 WT/LG* SPEED CONTROL RESUME SWITCH
15 TN INJECTOR DRIVER
#2
51 DB/YL*
AUTO SHUTDOWN
(ASD)
RELAY
-
RETURN
16
WT/DB*

INJECTOR DRIVER
#1
52 PK/BK
EVAP CANISTER PURGE SOLENOID
17 DB/TN INJECTOR DRIVER
#7
(V-8
ONLY) 53 LG/RD* SPEED CONTROL VENT SOLENOID
18 DB/GY
INJECTOR DRIVER
#8
(V-8
ONLY) 54
OR/BK* SHIFT INDICATOR LIGHT (MANUAL TRANSMISSION ONLY)
19 BK/GY*
IGNITION COIL DRIVER 54
OR/BK* CONVERTOR CLUTCH SOLENOID (AUTO TRANSMISSION)
20 DG
GENERATOR FIELD CONTROL 55
OR/WT OVERDRIVE SOLENOID (AUTO TRANSMISSION ONLY)
21 BK/RD
CHARGE TEMPERATURE SENSOR 56
GY/PK SRI LAMP
(5.9L HDC
ENGINE)
22
OR/DB*

THROTTLE POSITION SENSOR
(TPS)
57
DG/OR ASD SENSE
23 TN/WT
OXYGEN SENSOR SIGNAL
(5.9L HDC
ENGINE) 58 LG/BK
INJECTOR DRIVER
#6

24 GY/BK IGNITION (CAMSHAFT POSITION SENSOR) 59
VT/BK IAC MOTOR
#1

25 PK
,
SCI
TRANSMIT 60
YL/BK* IAC MOTOR
#3

26 CCD
(-:-)
WIRE COLOR CODES LB
LIGHT BLUE
VT VIOLET

27 BR
A/C SWITCH SENSE BK BLACK
LG LIGHT GREEN
WT

WHITE
28 VT A/C SELECT BR BROWN
OR ORANGE
YL YELLOW
29 WT/PK* BRAKE SWITCH
-
DB DARK BLUE PK
PINK *
WITH TRACER
30 BY/YL*
PARK/NEUTRAL SWITCH DG DARK GREEN
RD
RED
31 GY
GRAY TN TAN
32 BK/PK*
MALFUNCTION INDICATOR LAMP
33 TN/RD*
SPEED CONTROL VACUUM SOLENOID CONNECTOR
34 DB/OR* A/C CLUTCH RELAY TERMINAL

|(pcKX>coooop0ffoj'
oooooooooojj
35 GY/YL*
EGR SOLENOID SHOWN W'41
30
50«M#5l31
604

%\
oooooooooo ••ooooooooooj

36 J9314-171
Fig.
17 PCM
Connector—Gas
Powered
Engines

•

THROTTLE

POSITION
SENSOR
CO

Fig. 18 System Schematic—3.9L (V-6) Engine
CO

CJ1
m
r-

co
-<

CO

J9314-120

Fig. IS System Schematic—5.2U5.9L LDC (V-8) Engine

-<

m

J9314-172

Fig.
20 System
Schematic-SSL
HDC (V-8) Engine

14-52
FUEL
SYSTEM

•
CAMSHAFT
POSITION
SENSOR
TESTING

Refer to Group 8D, Ignition Systems for testing.

COOLANT
TEMPERATURE
SENSOR
TEST
To perform a complete test of the engine coolant
temperature sensor and its circuitry, refer to DRB II
tester and appropriate Powertrain Diagnostics Proce­
dures manual. To test the sensor only, refer to the
following: (1) Disconnect wire harness connector from coolant
temperature sensor (Fig. 21). Engines with air conditioning; When removing
the connector from sensor, do not pull directly on
wiring harness. Fabricate an L-shaped hook tool
from a coat hanger (approximately eight inches
long).
Place the hook part of tool under the connector
for removal. The connector is snapped onto the sen­ sor. It is not equipped with a lock type tab.
Fig.
21
Engine
Coolant
Temperature

Sensor—
Typical
(2) Test the resistance of the sensor with a high in­
put impedance (digital) volt-ohmmeter. The resis­
tance (as measured across the sensor terminals) should be less than 1340 ohms with the engine
warm. Refer to the Coolant Temperature sensor/ Charge Air Temperature sensor resistance chart. Re­
place the sensor if it is not within the range of resistance specified in the chart.
(3) Test continuity of the wire harness. Do this be­
tween the powertrain control module (PCM) wire
harness connector terminal 2 and the sensor connec­
tor terminal. Also test continuity of wire harness ter­
minal 4 to the sensor connector terminal. Repair the
wire harness if an open circuit is indicated.
(4) After tests are completed, connect electrical
connector to sensor. The sensor connector is symmet­
rical (not indexed). It can be installed to the sensor in either direction. SENSOR RESISTANCE (OHMS)-COOLANT
TEMPERATURE SENSOR/CHARGE AIR TEMPERATURE SENSOR

TEMPERATURE
RESISTANCE
(OHMS)

C F
MIN MAX
-40 -40 291,490 381,710
-20 -4 85,850 108,390
-10 14 49,250 61,430
0 32 29,330 35,990
10 50 17,990 21,810
20 68 11,370 13,610
25 77 9,120 10,880
30 86 7,370 8,750
40 104 4,900 5,750
50 122 3,330 3,880
60 140 2,310 2,670
70 158 1,630 1,870
80 176 1,170 1,340
90 194 860 970
100 212 640 720
no 230 480 540
120 248 370 410

J928D-4

CHARGE
AIR
TEMPERATURE SENSOR TEST
To perform a complete test of the intake manifold
charge air temperature sensor and its circuitry, refer
to DRB II tester and appropriate Powertrain Diag­ nostics Procedures manual. To test the sensor only,
refer to the following: (1) Disconnect the wire harness connector from the
charge air temperature sensor (Fig. 22).
Fig.
22
Charge
Air
Temperature
Sensor—Typical
(2) Test the resistance of the sensor with an input
impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be
less than 1340 ohms with the engine warm. Refer to
the Coolant Temperature sensor/Charge Air Temper-

•

FUEL
SYSTEM
14-53 ature sensor resistance chart. Replace the sensor if it
is not within the range of resistance specified in the chart. (3) Test the resistance of the wire harness. Do this
between the powertrain control module (PCM) wire
harness connector terminal 21 and the sensor connec­ tor terminal. Also check between terminal 4 to the sensor connector terminal. Repair the wire harness
as necessary if the resistance is greater than 1 ohm.

MANIFOLD
ABSOLUTE
PRESSURE
(MAP)
SENSOR

TEST
To perform a complete test of MAP sensor (Fig. 23)
and its circuitry, refer to DRB II tester and appropri­
ate Powertrain Diagnostics Procedures manual. To
test the MAP sensor only, refer to the following: (1) Inspect the rubber L-shaped fitting from the
MAP sensor to the throttle body (Fig. 24). Repair as necessary.
MANIFOLD
ABSOLUTE

Fig.
23 Manifold
Absolute
Pressure
(MAP)
Sensor—
Typical
CAUTION:
When testing the MAP
sensor,
be
sure

that
the
harness
wires are not
damaged
by the test
meter
probes.

(2) Test the MAP sensor output voltage at the
MAP sensor connector between terminals A and B (Fig. 25). With the ignition switch ON and the en­
gine OFF, output voltage should be 4-to-5 volts. The
voltage should drop to
1.5-to-2.1
volts with a hot,
neutral idle speed condition.
(3) Test powertrain control module (PCM) pin-1 for
the same voltage described above to verify the wire
harness condition. Repair as necessary.
Fig.
24
Rubber
L-Shaped
Fitting—MAP
Sensor-to-

Throttle
Body

A.
Ground
B.
Output Voltage

C.
5
Volts
J8914-91

Fig.
25 MAP
Sensor
Connector
Terminals—Typical
(4)
Test MAP sensor supply voltage at sensor con­
nector between terminals A and C (Fig. 25) with the ignition ON. The voltage should be approximately 5
volts (±0.5V). Five volts (±0.5V) should also be at
terminal 6 of the powertrain control module (PCM)
wire harness connector. Repair or replace the wire
harness as necessary.
(5) Test the MAP sensor ground circuit at sensor
connector terminal A (Fig. 25) and PCM connector
terminal/pin-4. Repair the wire harness if necessary.
(6) Test the MAP sensor ground circuit at the
PCM connector between terminal/pin-4 and terminal/
pin-11 with an ohmmeter. If the ohmmeter indicates an open circuit, inspect for a defective sensor ground
connection. Refer to Group 8W, Wiring Diagrams for
location of this connection. If the ground connection